Volvo Trucks North America Greensboro, NC USA DService Bulletin Trucks Date Group No. Page 1.2007 254 34 1(23) Diesel Particulate Filter System Maintenance D16F Diesel Particulate Filter System, Maintenance W2005786 This information covers the maintenance of the Diesel Particulate Filter (DPF) on a vehicle equipped with a Volvo D16F engine. Contents Special Tools page 2. Particulate Filter, Clean page 3. Note: Information is subject to change without notice. Illustrations are used for reference only, and may differ slightly from the actual vehicle being serviced. However, key components addressed in this information are represented as accurately as possible. PV776-20177385 USA23053.ihval
Service Bulletin 1.2007 254 34 2(23) Special Tools For special tools ordering instructions, refer to Tools Information, group 08. W0002405 J48112 Diesel Particulate Filter Cleaner W0002398 85111327 DPF Support Stand
Service Bulletin 1.2007 254 34 3(23) 2545-11-02-03 Particulate Filter, Clean You must read and understand the precautions and guidelines in Service Information, group 20, "General Safety Practices, Engine" before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. Filter Maintenance The ceramic Diesel Particulate Filter (DPF) must be removed from the muffler canister and cleaned to remove the accumulation of particulate matter (PM) which is mostly soot and ash deposits. Special equipment is required to properly clean all the particulate matter from the small surfaces of the ceramic DPF. If the filter is not clean, it will become clogged and increase exhaust back pressure. As back pressure increases, engine power and economy decline as does the ability of the system to remove undesirable emissions. Volvo uses two different designs for the DPF systems. These include the following: Compact Vertical Back of Cab Compact DPF DPF Filter Removal 1 Apply the parking brake and place the shift lever in neutral. 2 Remove all cables from ground (negative) battery terminals to prevent personal injury from electrical shock. W2003815
Service Bulletin 1.2007 254 34 4(23) 3 Remove the right side chassis fairing, if equipped. W2005915 4 Remove the bolts and nuts securing braces and/or steps located between the angle wing brackets and remove. W2005956 5 Remove outlet and mid-temperature sensors and P-clamps used to secure temperature sensor harnesses. Also, remove both pressure differential sensor tubes. W2006027
6 Service Bulletin 1.2007 254 34 5(23) Using a marker, make alignment marks on each of the module sections, above and below each band clamp. W2005818 7 Remove the lower exhaust V-band clamp that connects the DPF outlet module to the exhaust pipe. Also, remove the V-band clamp that connects the catalyst module to the filter module. W2006026 8 Position a flat surface jack with a very stable support (such as a transmission jack) under the base of the DPF. W2005912
9 Service Bulletin 1.2007 254 34 6(23) Remove the fasteners which secure the DPF lower supporting bracket to the chassis frame bracket. This will release the weight of the DPF lower portion onto the transmission jack. Note: Removing the lower bracket will release the weight. Ensure the transmission jack is properly positioned and level. W2005908 10 Lower and roll the transmission jack out from the right side of the chassis to remove the lower portion of DPF. 11 Loosen the nut securing the large V-band clamp between the exhaust outlet module and the filter module. W2005798
12 Service Bulletin 1.2007 254 34 7(23) Lift to remove the diesel particulate filter module from the outlet module. Remove and discard the high temperature gasket. CAUTION The following precautions should be considered before handling the Diesel Particulate Filter (DPF) muffler components: A. Wear suitable eye protection. B. Wear suitable overalls or apron and heavy-duty gloves to avoid skin contact. C. Wear suitable respirator to avoid inhalation. D. Ensure adequate ventilation. W2005810 13 Prepare the DPF filter to be air pressure cleaned in special cleaning equipment such as J48112 (Diesel Particulate Filter Cleaner) or equivalent. Follow the cleaning equipment manufacturer s instructions on how to best clean the filter. 14 Inspect the two band clamps for galled threads, cracks or heat-damaged areas. Replace any clamp found to contain any irregularity. DPF Filter Installation 1 Before installation, clean all gasket sealing surfaces of the filter, catalyst and outlet modules. Place a new high temperature gasket on the clean outlet module sealing surface. W2005800
2 Service Bulletin 1.2007 254 34 8(23) Align the marks made at disassembly and carefully lower the filter module (with new gasket) into the outlet module opening. Note: Make sure the high temperature gasket remains in place and has not become dislodged. W2005810 3 Install the large V-band clamp over the filter module and position the clamp to allow the tightening nut to align with the exhaust outlet port. Allow the V-band clamp to remain loose at this time. 4 Place a new high temperature gasket on top of the filter module. W2005800
5 Service Bulletin 1.2007 254 34 9(23) Using the transmission jack, lift the lower section of the DPF muffler into position next to the chassis frame bracket. W2005908 6 Perform the following steps to align and lift the filter and outlet module assembly into position: Align the outlet module flange to the exhaust pipe. Align the locator tab at the top of the filter module with the slot located in the bottom of the catalyst module. Start all fasteners that connect the lower supporting bracket to the chassis frame bracket. Note: Make sure the high temperature gasket remains in place and has not become dislodged. W2005801 7 Install the large V-band clamp onto the catalyst module and secure the catalyst module to the filter module. Position the clamp to allow the tightening nut to align with the exhaust outlet port. Both clamps should now align. Torque-tighten the clamp fastener to 20 Nm (177 in-lb). 20 Nm (177 in-lb) W2005797
8 Service Bulletin 1.2007 254 34 10(23) Install the lower exhaust V-band clamp that connects the outlet module to the exhaust pipe. Torque-tighten the clamp fastener to 7 ± 2 Nm (62 ± 18 in-lb). Note: Inspect clamps for galled threads or deformed clamping surfaces. Replace clamps as required. 7±2Nm (62 ± 18 in-lb) W2005911 9 Secure the DPF bracket to the chassis frame bracket. Torque-tighten the fasteners to 48 ± 8 Nm (35 ± 6 ft-lb). Remove the transmission jack. 48 ± 8 Nm (35 ± 6 ft-lb) W2005908 10 Install outlet and mid-temperature sensors and P-clamps used to secure temperature sensor harnesses. Also, install both pressure differential sensor tubes. Torque-tighten to specifications. Note: A high temperature anti-seizing compound should always be applied to the threads of sensors, plugs or fittings in the exhaust system to avoid component seizure or corrosion. W2006027
11 Service Bulletin 1.2007 254 34 11(23) Position the connector braces and/or steps located between the angle wing brackets and secure using bolts and nuts. Torque-tighten to specification. W2005956 12 Reinstall the right side chassis fairing, if equipped. W2005915 13 Install all previously removed cables to the ground (negative) battery terminals. W2003815 14 Start the engine, check for leaks and proper operation. Fault codes may need to be cleared at this time.
Vertical Back of Cab Service Bulletin 1.2007 254 34 12(23) DPF Filter Removal 1 Apply the parking brake and place the shift lever in neutral. 2 Remove all cables from ground (negative) battery terminals to prevent personal injury from electrical shock. W2003815 3 Remove the heat shield from the Diesel Particulate Filter (DPF) muffler. W2005986 4 Loosen the clamps and remove the exhaust stack from the DPF muffler outlet. W2005987
5 Service Bulletin 1.2007 254 34 13(23) Remove the lower exhaust V-band clamp at the exhaust elbow. W2005988 6 Remove the P-clamp fasteners that secure the DPF muffler harness to the muffler stanchion and release the harness from the stanchion. W2005989 7 Cut all tie straps securing the DPF muffler harness.
8 Service Bulletin 1.2007 254 34 14(23) Disconnect the harness connectors from the pressure differential and NO x sensors. W2005990 9 Disconnect the harness connectors from all temperature sensors on the DPF muffler. 10 Support the weight of the DPF muffler using a mobile floor crane such as OTC 16-1815 or equivalent crane capable of safely lifting the muffler. Position the crane and attach a chain using bolts, nuts and washers to the lifting eyes of the muffler. W2005991
11 Service Bulletin 1.2007 254 34 15(23) Remove the lower support band clamp from the DPF muffler. W2005992 12 Remove the upper band clamp mounting bolts and remove the mounting bracket from the stanchion. Note: Removing the upper band clamp mounting bracket will release the weight of the DPF. Ensure the floor crane and chain are properly positioned. W2005993 13 With assistance, lift and remove the DPF muffler assembly from the truck W2006002
14 Service Bulletin 1.2007 254 34 16(23) With assistance, place the muffler assembly in muffler support stand 85111327. 85111327 W2006001 15 Remove the pressure differential tube from the catalyst. W2005995 16 Remove the V-band clamp securing the outlet module to the filter module. W2005996
17 Service Bulletin 1.2007 254 34 17(23) With assistance, use a mobile floor crane to remove the outlet module from the DPF filter. W2006000 18 Remove the V-band clamp securing the filter module to the catalyst module. W2005998 19 Remove the DPF filter module from the catalyst module. CAUTION The following precautions should be considered before handling the Diesel Particulate Filter (DPF) muffler components: A. Wear suitable eye protection. B. Wear suitable overalls or apron and heavy-duty gloves to avoid skin contact. C. Wear suitable respirator to avoid inhalation. D. Ensure adequate ventilation.
Service Bulletin 1.2007 254 34 18(23) 20 Prepare the DPF filter to be air pressure cleaned in special cleaning equipment such as J48112 (Diesel Particulate Filter Cleaner) or equivalent. Follow the cleaning equipment manufacturer s instructions on how to best clean the filter. 21 Inspect the two band clamps for galled threads, cracks or heat-damaged areas. Replace any clamp found to contain any irregularity. DPF Filter Installation 1 Before installation, clean all gasket surfaces of the filter, catalyst and outlet modules. 2 Install a new gasket onto the top of the catalyst module. W2005800 3 Align the locator tab located on the bottom of the filter module with the slot located in the top of the catalyst module. Install the DPF filter onto the catalyst and secure the two modules together using a V-band clamp tightened securely. Note: Make sure the high temperature gasket remains in place and has not become dislodged. W2005801
Service Bulletin 1.2007 254 34 19(23) 4 Install a new gasket onto the top of the filter module. W2005800 5 With assistance, use a mobile floor crane to install the outlet module onto the DPF filter. Ensure that the differential pressure tube does not become damaged during outlet module installation. Note: Make sure the high temperature gasket remains in place and has not become dislodged. W2006000 6 Install the V-band clamp securing the outlet module to the filter module and tighten clamp fasteners securely. All clamps should now be aligned and tightened. W2005997
7 Service Bulletin 1.2007 254 34 20(23) Install the pressure differential tube to the catalyst port and tighten the fitting securely. Note: A high temperature anti-seizing compound should always be applied to the threads of sensors, plugs or fittings in the exhaust system to avoid component seizure or corrosion. W2005995 8 Lift the weight of the DPF muffler using a mobile floor crane and with assistance, position the muffler next to the frame-mounted stanchion, at the back of the cab. W2006002 9 Align the slot in the muffler bottom with the tab on the stanchion. W2006003
Service Bulletin 1.2007 254 34 21(23) 10 Perform the following steps to align the DPF muffler into final position on the muffler stanchion: Align the muffler inlet with the exhaust elbow. Align the muffler upper supporting bracket to the stanchion and install bolts loose. Loosely install the upper supporting band clamp with attached bracket and install bracket bolts into the stanchion. Loosely install the lower supporting band clamp. 11 With all components aligned, install and secure the lower V-band clamp at the inlet side of the muffler. W2005988 12 Install the muffler heat shield onto the DPF muffler. W2005986 13 Secure all fasteners and clamps that connect the DPF muffler to the stanchion. Torque-tighten all clamps and muffler fasteners to specifications. 14 Disconnect crane and remove lifting chain from muffler.
15 Service Bulletin 1.2007 254 34 22(23) Reconnect the harness connectors for the pressure differential and NO x sensors. W2005990 16 Reconnect the harness connectors for all temperature sensors on the DPF muffler. 17 Install the P-clamp fasteners that secure the DPF muffler harness to the muffler stanchion. W2005989 18 Secure the harness using tie straps.
19 Service Bulletin 1.2007 254 34 23(23) Install the exhaust stack onto the DPF muffler and secure using two clamps. Tighten-tighten clamps to specification. W2005987 20 Install all previously removed cables to the ground (negative) battery terminals. W2003815 21 Start the engine, check for exhaust leaks and proper operation. 22 Clear fault codes if necessary.